Travel Time – The Hidden Cost in Warehouse Productivity

Doncaster-based logistics consultancy Aspire-360 is encouraging local supply chain and warehouse leaders to take a fresh look at how travel time impacts productivity across their sites.

Founder and Managing Director Mike Robson, who spent more than 20 years leading innovation and operational improvement projects across Europe for one of the world’s largest logistics providers, says the same challenge appears time and again.

“When we analyse warehouse performance, the numbers are remarkably consistent — around 40% of a picker’s shift can be spent simply walking between tasks. That’s a huge amount of paid time not directly adding value,” explains Mike.

Aspire-360’s work with UK distribution centres has shown that the main causes are often found before and after the actual picking process — such as inefficient roll-cage marshalling, poor zone design, or replenishment tasks competing with picking routes.

“The good news,” Mike adds, “is that these are often the easiest areas to fix. Simple layout changes, better task sequencing or smarter use of digital tools can reclaim significant productivity without major investment.”

By helping operations identify and quantify these hidden inefficiencies, Aspire-360 aims to support local businesses in boosting performance and competitiveness across Yorkshire’s thriving logistics sector.

Mike concludes:

“Having spent my career on the warehouse floor and in boardrooms, I’ve seen that productivity isn’t just about working harder — it’s about working smarter.”

For more information or to share experiences on improving warehouse productivity, visit www.aspire-360.co.uk